End Post Gap Fill Assembly

ABSTRACT

An end post gap fill assembly for an insulated rail joint includes a gap fill member including a head section at a first end of the gap fill member and a stem section extending from the head section to a second end of the gap fill member. The head section is configured to be positioned between respective head portions of first and second rails and the stem section is configured to be positioned between respective web portions and base portions of the first and second rails. A thickness of the gap fill member is consistent from the first end of the gap fill member to the second end of the gap fill member. A sealant is configured to fill a circumferential gap between an outer surface of the gap fill member and outer surfaces of the first and second rails.

CROSS REFERENCE TO RELATED APPLICATION

This application claims benefit of U.S. Provisional Application No. 63/253,761, filed on Oct. 8, 2021, the disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates to insulated rail joints and, more particularly, to an end post gap fill assembly for an insulated rail joint.

Description of Related Art

A rail system is generally divided into sections or blocks for detecting trains which permit more trains to travel on one stretch of track or railroad rails. Each section is electrically isolated from all other sections so that when no train is present, a high electrical resistance can be measured over the parallel railroad rails in that section. When a train enters the section, the train short circuits adjacent railroad rails and the electrical resistance drops, thus indicating that a train is in that section.

Railroad tracks are created generally by welding railroad rails to each other or by attaching railroad rails to each other with a steel joint. High-performance, non-metallic joints are typically used for electrically-isolating adjacent rail sections of a rail system in order to create an electrically-isolated section. However, the non-metallic joints are very expensive due to the special high-performance material needed to endure the high tensile and flexural forces exerted on a rail joint as the wheels of a locomotive or rail car pass over the joint. An alternative to a non-metallic joint is a steel rail joint having electrically-insulating material, such as epoxy or resin affixed to the rail joint surface for isolating rail sections.

However, these epoxies and resins must be able to endure the high tensile, temperature change, and flexural forces exerted on the railroad rails in order to prevent the electrically-insulating material from peeling off the rail joint. Over time, the rail wheels will cause the rail ends to deform and/or break apart, thus causing an insulation failure and incorrect signaling. This can cause significant and unnecessary delays in train journeys, thereby adversely affecting the efficiency of the rail service.

One existing repair process includes filling the joint with the epoxies or resins. However, this repair process does not provide the proper compression resistant properties and the rail joint soon fails again.

SUMMARY OF THE INVENTION

In one aspect or embodiment, an end post gap fill assembly for an insulated rail joint including a first rail, a second rail aligned with the first rail and defining an end post gap between ends of the first rail and the second rail, a first rail joint bar, and a second rail joint bar, the first rail and the second rail each including a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, with the end post gap fill assembly including a gap fill member having a first end, a second end positioned opposite the first end, a first face configured to abut the end of the first rail, and a second face configured to abut the end of the second rail. The gap fill member includes a head section at the first end of the gap fill member and a stem section extending from the head section to the second end of the gap fill member, with the head section configured to be positioned between the respective head portions of the first and second rails and the stem section configured to be positioned between the respective web portions and base portions of the first and second rails. The gap fill member has a length extending along a longitudinal axis of the gap fill member, a width extending perpendicularly to the longitudinal axis of the gap fill member, and a thickness extending from the first face to the second face, with the thickness of the gap fill member consistent from the first end of the gap fill member to the second end of the gap fill member. The end post gap fill assembly also includes a sealant configured to fill a circumferential gap between an outer surface of the gap fill member and outer surfaces of the first and second rails.

The gap fill member may include a high pressure fiberglass laminate, where the gap fill member and the sealant are electrically insulating. The width of the gap fill member at the head section may be smaller than a width of the first and second rails at the head portions of the first and second rails. The width of the gap fill member at the stem section may be smaller than a width of the first and second rails at the web portions of the first and second rails. The length of the gap fill member may be smaller than a height of the first and second rails extending from a top surface of the head portions of the first and second rails to a bottom surface of the base portions of the first and second rails. The first and second rails may be 115 RE railroad rail. The first and second rails may be 136 RE railroad rail. The end post gap fill assembly may further include tape configured to be applied to the head portions of the first and second rails to contain the sealant to the circumferential gap.

In a further aspect or embodiment, a method of filling an end post gap for an insulated rail joint including a first rail, a second rail aligned with the first rail and defining an end post gap between ends of the first rail and the second rail, a first rail joint bar, and a second rail joint bar, the first rail and the second rail each including a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, with the method including: inserting a gap fill member into the end post gap. The gap fill member having a first end, a second end positioned opposite the first end, a first face abutting the end of the first rail, and a second face abutting the end of the second rail, with the gap fill member including a head section at the first end of the gap fill member and a stem section extending from the head section to the second end of the gap fill member. The head section is positioned between the respective head portions of the first and second rails and the stem section is positioned between the respective web portions and base portions of the first and second rails. The gap fill member having a length extending along a longitudinal axis of the gap fill member, a width extending perpendicularly to the longitudinal axis of the gap fill member, and a thickness extending from the first face to the second face, with the thickness of the gap fill member consistent from the first end of the gap fill member to the second end of the gap fill member. The gap fill member defining a circumferential gap between an outer surface of the gap fill member and outer surfaces of the first and second rails. The method further including: filling the circumferential gap with a sealant, where the sealant is electrically insulating.

The method may further include applying tape to at least a portion of the first and second rails prior to filling the circumferential gap with sealant, with the tape configured to contain the sealant to the circumferential gap. The method may further include trimming the gap fill member to size prior to inserting the gap fill member into the end post gap. The stem section at the second end of the gap fill member may be trimmed to reduce the length of the gap fill member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a gap fill member according to one aspect or embodiment of the present application;

FIG. 2 is a cross-sectional view of an insulated rail joint and an end post gap fill assembly according to one aspect or embodiment of the present application;

FIG. 3 is a cross-sectional view of an insulated rail joint and an end post gap fill assembly according to a further aspect or embodiment of the present application; and

FIG. 4 is a side view of the insulated rail joint and the end post gap fill assembly of FIG. 2 .

DESCRIPTION OF THE INVENTION

For purposes of the description hereinafter, the words “upward” and “downward”, and like spatial terms, if used, shall relate to the described embodiments as oriented in the drawing figures. However, it is to be understood that many alternative variations and embodiments may be assumed except where expressly specified to the contrary. It is also to be understood that the specific devices and embodiments illustrated in the accompanying drawings and described herein are simply exemplary embodiments of the invention.

Referring to FIGS. 1-4 , in one aspect or embodiment, an end post gap fill assembly 10 for an insulated rail joint 12 includes a gap fill member 14 and sealant 16. The end post gap fill assembly 10 is configured to be utilized in connection with an existing, installed insulated rail joint 12. In one aspect or embodiment, the end post gap fill assembly 10 is utilized in connection with an insulated rail joint 12 that has failed or de-bonded and is missing at least a portion of an end post of the insulated rail joint 12. As shown in FIGS. 2-4 , the insulated rail joint 12 includes a first rail 18, a second rail 20 aligned with the first rail 18 and defining an end post gap 22 between ends of the first rail 18 and the second rail 20, a first rail joint bar 24, and a second rail joint bar 26. The first rail 18 and the second rail 20 each include a head portion 28, a web portion 30 extending from the head portion 28, and a base portion 32 extending from the web portion 30. The insulated rail joint 12 may also include an insulating sleeve 34, such as a fiberglass sleeve, and an adhesive between the respective first and second rail joint bars 24, 26 and the first and second rails 18, 20.

Referring again to FIGS. 1-4 , the gap fill member 14 has a first end 52, a second end 54 positioned opposite the first end 52, a first face 56 configured to abut the end of the first rail 18, and a second face 58 configured to abut the end of the second rail 20. The gap fill member 14 includes a head section 60 at the first end 52 of the gap fill member 14 and a stem section 62 extending from the head section 28 to the second end 54 of the gap fill member 14, with the head section 60 configured to be positioned between the respective head portions 28 of the first and second rails 18, 20 and the stem section 62 configured to be positioned between the respective web portions 30 and base portions 32 of the first and second rails 18, 20. The gap fill member 14 has a length extending along a longitudinal axis of the gap fill member 14, a width extending perpendicularly to the longitudinal axis of the gap fill member 14, and a thickness extending from the first face 56 to the second face 58, with the thickness of the gap fill member 14 consistent from the first end 52 of the gap fill member 14 to the second end 54 of the gap fill member 14. In one aspect or embodiment, the thickness of the gap fill member 14 is 3/16″, ⅜″, or between 3/16″ and ⅜″. The head section 60 of the gap fill member 14 is wider than the stem section 62 of the gap fill member 14.

In one aspect or embodiment, one or more gap fill members 14 are utilized to fill the end post gap 22 between the ends of the first and second rails 18, 20. As discussed in more detail below, the sealant 16 is configured to fill a circumferential gap 70 between an outer surface of the gap fill member 14 and outer surfaces of the first and second rails 18, 20.

The sealant 16 may be liquid or liquid-like when applied, but solidifies during installation. The sealant 16 may be configured to bond to the first and second rails 18, 20, the gap fill member 14, and/or the first and second rail joint bars 24, 26. The sealant 16 may be an adhesive material, including polyurethane-based materials. The sealant 16 may be a polymer based material, polyurethane, epoxy, silicone, acrylics, or curing acrylic or epoxy. The sealant 16 may bond and solidify within the circumferential gap 70. The sealant 16 may be selected by virtue of its properties, such as adhesion, strength, time to solidify, and flexibility to withstand tensile and compressive stresses. In one aspect or embodiment, the gap fill member 14 and the sealant 16 are electrically insulating.

In one aspect or embodiment, the gap fill member 14 is formed from a pressure resistant material, such as a high pressure fiberglass laminate, although other suitable materials may be utilized. In one aspect or embodiment, the gap fill member 14 is formed from G10 fiberglass material.

Referring to FIGS. 2 and 3 , in one aspect or embodiment, the width of the gap fill member 14 at the head section 60 is smaller than a width of the first and second rails 18, 20 at the head portions 28 of the first and second rails 18, 20. In one aspect or embodiment, the width of the gap fill member 14 at the stem section 62 is smaller than a width of the first and second rails 18, 20 at the web portions 30 of the first and second rails 18, 20. In one aspect or embodiment, the length of the gap fill member 14 is smaller than a height of the first and second rails 18, 20 extending from a top surface of the head portions 28 of the first and second rails 18, 20 to a bottom surface of the base portions 32 of the first and second rails 18, 20. In FIG. 2 , the end post gap fill assembly 10 is shown in connection with the insulated rail joint 12 where the first and second rails 18, 20 are each 115 RE railroad rails. In FIG. 3 , the end post gap fill assembly 10 is shown in connection with the insulated rail joint 12 where the first and second rails 18, 20 are each 136 RE railroad rails. However, the first and second rails 18, 20 can be any size or type of standard tee railroad rail, such as but not limited to 132 RE, 136 RE and 141 RE rails according to the American Railway Engineering and Maintenance-of-Way Association (AREMA) specifications. In one aspect or embodiment, the end post gap fill assembly 10 includes tape 72 configured to be applied to the head portions 28 of the first and second rails 18, 20 to contain the sealant 16 to the circumferential gap 70, which is discussed in additional detail below. In one aspect or embodiment, the tape 72 is electrically insulating.

Referring to FIGS. 2-4 , in one aspect or embodiment, a method of filling the end post gap 22 of the insulated rail joint 12 includes: inserting the gap fill member 14 into the end post gap 22, with the first face 56 abutting the end of the first rail 18 and the second face 58 abutting the end of the second rail 20, the head section 60 positioned between the respective head portions 28 of the first and second rails 18, 20, and the stem section 62 positioned between the respective web portions 30 and the base portions 32 of the first and second rails 18, 20; and filling the circumferential gap 70 with the sealant 16.

In one aspect or embodiment, the method includes applying the tape 72 to at least a portion of the first and second rails 18, 20 prior to filling the circumferential gap 70 with sealant 16, with the tape 72 configured to contain the sealant 16 to the circumferential gap 70. For example, the tape 72 may be applied to a portion of the head portions 28 of the first and second rails 18, 20 and/or the base portions 32 of the first and second rails 18, 20 to act as a form as the sealant 16 is pumped or delivered to the circumferential gap 70.

In one aspect or embodiment, the method further includes trimming the gap fill member 14 to size prior to inserting the gap fill member 14 into the end post gap 22. The stem section 62 at the second end 54 of the gap fill member 14 may be trimmed to reduce the length of the gap fill member 14. The gap fill member 14 may be trimmed to accommodate the size or configuration of the insulated rail joint 12 or to accommodate any portions of an end post that may remain in the end post gap 22 between the first and second rails 18, 20.

The first and second rails 18, 20, particularly the head portions 28, may be altered prior to inserting the gap fill member 14 into the end post gap 22. Altering may include grinding or shaping to better form the appropriate structure needed for proper installation. The gap fill member 14 may be installed by inserting it downward between the first and second rails 18, 20 at the end post gap 22. The tape 72 may be removed after filling the circumferential gap 70 with the sealant 16, and the sealant 16 may be altered to conform to the shape of the first and second rails 18, 20.

The end post gap fill assembly 10 is configured to at least temporarily fill the end post gap 22 between the first and second rails 18, 20 after the insulated rail joint 12 has failed and/or lost at least a portion of its end post. The end post gap fill assembly 10 is configured to maintain the electrical insulation between the first and second rails 18, 20 until the insulated rail joint 12 can be entirely replaced. The end post gap fill assembly 10 is configured to provide a solid compression stop when the rails 18, 20 warm up and compress together, thereby preventing the sealant from being pushed out of the end post gap 22 or deteriorated due to such compression.

Further, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the foregoing description. Accordingly, the particular embodiments described in detail herein are illustrative only, and are not limiting to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. 

The invention claimed is:
 1. An end post gap fill assembly for an insulated rail joint, the insulated rail joint comprising a first rail, a second rail aligned with the first rail and defining an end post gap between ends of the first rail and the second rail, a first rail joint bar, and a second rail joint bar, the first rail and the second rail each comprising a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, the end post gap fill assembly comprising: a gap fill member having a first end, a second end positioned opposite the first end, a first face configured to abut the end of the first rail, and a second face configured to abut the end of the second rail, the gap fill member comprising a head section at the first end of the gap fill member and a stem section extending from the head section to the second end of the gap fill member, the head section configured to be positioned between the respective head portions of the first and second rails and the stem section configured to be positioned between the respective web portions and base portions of the first and second rails, the gap fill member having a length extending along a longitudinal axis of the gap fill member, a width extending perpendicularly to the longitudinal axis of the gap fill member, and a thickness extending from the first face to the second face, the thickness of the gap fill member is consistent from the first end of the gap fill member to the second end of the gap fill member; and a sealant configured to fill a circumferential gap between an outer surface of the gap fill member and outer surfaces of the first and second rails.
 2. The end post gap fill assembly of claim 1, wherein the gap fill member comprises a high pressure fiberglass laminate, and wherein the gap fill member and the sealant are electrically insulating.
 3. The end post gap fill assembly of claim 1, wherein the width of the gap fill member at the head section is smaller than a width of the first and second rails at the head portions of the first and second rails.
 4. The end post gap fill assembly of claim 3, wherein the width of the gap fill member at the stem section is smaller than a width of the first and second rails at the web portions of the first and second rails.
 5. The end post gap fill assembly of claim 4, wherein the length of the gap fill member is smaller than a height of the first and second rails extending from a top surface of the head portions of the first and second rails to a bottom surface of the base portions of the first and second rails.
 6. The end post gap fill assembly of claim 5, wherein the first and second rails comprise a 115 RE railroad rail.
 7. The end post gap fill assembly of claim 5, wherein the first and second rails comprise a 136 RE railroad rail.
 8. The end post gap fill assembly of claim 1, further comprising tape configured to be applied to the head portions of the first and second rails to contain the sealant to the circumferential gap.
 9. A method of filling an end post gap for an insulated rail joint, the insulated rail joint comprising a first rail, a second rail aligned with the first rail and defining an end post gap between ends of the first rail and the second rail, a first rail joint bar, and a second rail joint bar, the first rail and the second rail each comprising a head portion, a web portion extending from the head portion, and a base portion extending from the web portion, the method comprising: inserting a gap fill member into the end post gap, the gap fill member having a first end, a second end positioned opposite the first end, a first face abutting the end of the first rail, and a second face abutting the end of the second rail, the gap fill member comprising a head section at the first end of the gap fill member and a stem section extending from the head section to the second end of the gap fill member, the head section positioned between the respective head portions of the first and second rails and the stem section positioned between the respective web portions and base portions of the first and second rails, the gap fill member having a length extending along a longitudinal axis of the gap fill member, a width extending perpendicularly to the longitudinal axis of the gap fill member, and a thickness extending from the first face to the second face, the thickness of the gap fill member is consistent from the first end of the gap fill member to the second end of the gap fill member, the gap fill member defining a circumferential gap between an outer surface of the gap fill member and outer surfaces of the first and second rails; and filling the circumferential gap with a sealant, wherein the sealant is electrically insulating.
 10. The method of claim 9, further comprising: applying tape to at least a portion of the first and second rails prior to filling the circumferential gap with sealant, the tape configured to contain the sealant to the circumferential gap.
 11. The method of claim 9, further comprising: trimming the gap fill member to size prior to inserting the gap fill member into the end post gap.
 12. The method of claim 11, wherein the stem section at the second end of the gap fill member is trimmed to reduce the length of the gap fill member. 